Abu Dhabi: The place to be? Sky Park lift at Marina Sands ...

T H E V S L N E W S M A G A Z I N E • I S S U E T W O 2 0 1 0

NEWS

BUSINESS DEVELOPMENT

Abu Dhabi:The place to be?

Sky Park liftat Marina Sands

Cadagua viaduct

VSLNews2-2010_VSLNews2-2007 02/12/10 14:40 Page1

BRIDGES18

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hli

gh

ts

FACTS&TRENDS 6New market: First in Azerbaijan 6

Diaphragm walls: Patented solution 7

BUSINESS 4IMPROVEMENTHealth and safety: leading the way 4

SITE INSIGHTS 16Spain: Tailored design 18

Bulgaria: Weight lifting event 20

Malaysia: Johor approaches completion 22

Singapore: High-strength solution 24

COVER STORY 8Business development

Abu Dhabi: The new place to be?

FOCUS 27Seismic upgrade for historic viaduct

R&D 26How to avoid voids

Cover photo: Adnec Capital Tower, Abu Dhabi

NEWS, magazine published by VSL International Ltd. • Köniz, Switzerland Director of Publication: Daniel Rigout• [email protected] Editor in chief: Jane Rousseau •

[email protected] Editor : Elisabeth Lichter-Rodriguez • [email protected] Co-ordinators: Carlos Such, Emilie Parati, Doris Tong. Distribution: Myriam Doré •

[email protected] Design: Red Line Photos: Derek Allan, Philippe Guignard, Hervé Gouband, VSL staff, others Copyright: VSL 2010 •

TECH SHOW 32Think lateral for tandem launch

An ingenious and economical solution from

VSL has been used to install the four

structures that make up the Cadagua Link

toll road on Bilbao’s southern bypass.

HEAVYLIFTING

30

VOIDS26

STRUCTURES 32

TECHNICAL REPORT 30SkyPark – lifting a landmark

on Singapore’s Skyline

ABUDHABI 8


The worldwide economic crisis born of the fragility of our financial

institutions has seriously affected our markets, in particular through the

scaling down or postponement of many infrastructure projects across

all continents.

In the difficult environment of this highly competitive market, VSL has

maintained the quality of its long-term partnerships with its clients,

particularly by continuously striving for greater competitiveness.

This enduring confidence in VSL results from our strong values in the

service of our clients and partners: quality and safety at all times,

innovation and creativity for improved performance, relevant technical

solutions adapted to the most complex situations, and a strict adherence

to our commitments in terms of costs and time.

Today, as the world is back on track for growth, driven by the dynamic economies of Asia,

we continue to pursue our main goal: to make long-term partnerships with our clients a

focus of our strategy.

This shared ambition, which is based on the same core values and nourished by the new

opportunities that are arising, will allow each of the parties involved to capitalise on the

effects of the recovery.

Partners you can rely on

EDITORIALI S S U E T W O • 2 0 1 0

D a n i e l R i g o u t , C h a i r m a n a n d C E O


BUSINESS IMPROVEMENT

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W ith standards still varyingfrom country to countryand a working

environment that is constantlychanging, many hazards still exist.Many of the industry’s safetyissues such as falls from heightsremain the same as in the past -they just occur less frequently. VSL believes in the use ofestablished measures such astraining and seeks to changebehaviour so that everyone on sitesees safety as the norm. This meansto ‘design out risk’, eliminating thehazards in the first place.

Updating VSLequipmentCareful review of VSL equipmenthas led to a number ofenhancements in operationalsafety. Changes to the standardtwin grout mixer includedadditional protective covers as well

New logo: Safe, Around the

Clock, Around the World

VSL’s newsafety logohighlightsthree keymessages.

The healthand safety of

employees and thepublic are top priorities with‘Safe’ being at the top of thelogo. Safety awareness is a‘Around the Clock’ issue.Vigilance must be maintainedat all times. The third messageemphasises that VSL operates‘Around the World’ and expectsthe same high standardseverywhere. ■

Health and safety: leading the wayVSL Group’s policy is to “lead our business sector in terms of occupational

health and safety”. It takes a variety of actions for constant improvements.

ups on pumps. Pumps are nowquieter and have more oil storageand dual flow rates. Electricaldistribution panels adapted for siteuse allow easier, saferconnections. New hydrauliccutters make strand cutting saferand more efficient. Maintenancehas also been improved throughthe adoption of controlled sand-blasting instead of grinders toremove old paint.

PPE as standard

Personal Protective Equipment (orPPE) is the last line of defence.Items such as safety boots,helmets and masks also deal withlow-risk issues that have alreadybeen controlled as much as ispractical. Established rulesenforce the wearing of basicequipment in many situations and significant benefits are gainedfor a relatively small cost andinconvenience.

Staff involvementGroup-wide safety days areorganised every year and staffinvolvement is key to their success.They cover aspects such as theidentification of risks and featureexercises to highlight theimportance of procedures, includingfire and evacuation drills. ■

Pump EHPS-10 produces less noise and greater

oil delivery with higher capacity, dual flow

rates and improved hydraulic hose couplings.

Pump EHPS-3/4H features different couplers

for the pressure and return lines to avoid mix-

ups and is quieter than the older model.

as the provision of two emergencystop buttons. Similarly, hydraulicpushers benefit from an additionalremote control valve, movable tosuit working arrangements.Introducing distinct connectors forpressure and return lines has beendesigned to avoid coupling mix-


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Entering Hong Kong’srenowned Stanley dragonboat race is part of VSL

Intrafor Hong Kong’s efforts toincrease community involvementand have fun. Despite only a fewhours training, the team reachedthis year’s final, eventually coming8th out of 48 in their category – thetarget for 2011 is the top four! ■

Dragages Hong Kong, Byme,Asiaworld Expo and VSLIntrafor held a “funday” to

support sustainable developmentand local charities. Over 1,000people attended the event, whichwas also supported by manysuppliers and subcontractors. Theevent included charity stalls,information booths and gamessuch as a mini World Cup won byFT Laboratories. ■

S ustainability features highlyin the development of TataConsultancy Services’ new

20ha complex in Pune, India, withthe use of fly ash saving more than5,000t of cement. VSL India hasbeen awarded the design, supplyand installation of the 1,045t ofpost-tensioning for the project’sslabs and beams. Other “green”aspects include the use of bio-gasand daylight harvesting. ■

V SL Australia and EmergencyArchitects were among arecord 80,000 participants in

the 14km City2Surf race in Sydney.The 36 VSL entrants completed thescenic course from central Sydneyto Bondi Beach via a fiendishhalfway point, Heartbreak Hill.Their efforts were in support ofEmergency Architects projects andalso proved a great team-buildingopportunity. ■

V SL technology has enableddeteriorated corrugatedsteel pipes to be

strengthened while still in theground, avoiding disruptivereplacement. A joint venturebetween VSL Brunei andInsituform Asia Limited (IAL)carried out the contract using theCured in Place Pipes (CIPP)technique. The culverts run 15mbelow a major highway, carryingstormwater and run-off water tothe sea. Work took place at fourlocations and was completed inSeptember 2010. ■

Development of the VSLSaddle system for bridgeswon third prize for VSL in

the technical and R&D category ofthis year’s Bouygues ConstructionInnovation Competition. RachidAnnan and Thibault Collin-Delavaudrepresented VSL in the competition,which attracted 500 submissionsfrom more than 2,000 participantsvying for the 24 awards. ■

COMMUNITY

Enter thedragon… boat!

AWARDS

Success forVSL Saddlesystem

REPAIR

Culvert cure

ACTITUDES

Fundaysuccess

SUSTAINABLE

CONSTRUCTION

Slab savings

EMERGENCY SUPPORT

City2Surf 2010

Culvert before rehabilitation

Rehabilitation completed


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FACTS&TRENDS

> FT Laboratories - a

subsidiary of VSL International –

has been working with VSL HK

to carry out static load testing inHong Kong on GC tendonanchorages. The testing hadoriginally only been available inVSL’s test laboratory in Subingen,Switzerland. The tests studieddeformation characteristics ofloaded tendonsand involved the monitoring of parametersincluding strandelongation,wedgedisplacementand anchor-headdeflection. FT Laboratoriesserves as analternative base in Asia for in-house testing within the VSLgroup. It has been expanding itsscope of services to meet thechallenges of technicallydemanding projects in Taiwan,Vietnam and Dubai. ■ Contact:

[email protected]

> VSL Hong Kong was

awarded work on two cement

silos in Azerbaijan last year andbegan installation in May, with

NEW MARKET

First in AzerbaijanTesting services

In-house help completion scheduled forDecember. The project involvesprovision of transport andstorage facilities for both rawmeal and clinker on behalf ofowner Garadagh Cement OJSC,part of the Holcim Group. The main contractor is CBMIConstruction Co., Ltd (China).The 68.9m-high raw mealstorage silo is circular in shapewith a 15m internal diameter anda 500mm-thick wall. Its 53 pairsof horizontal post-tensioning useVSL GC6-12 tendons. The clinkersilo has a 47.25m internaldiameter, a wall thickness of450mm and stands 35m high. Ituses 62 pairs of VSL GC6-19tendons as horizontal post-tensioning. ■ Contact:

[email protected]

> Intrafor Hong Kong’s new

proprietary directional core

barrel is at work on its firstproject. Maeda-Crec-Seli JVawarded Intrafor the contract forground investigation along adrainage tunnel. The new barreldeveloped in 2009 is being usedfor a 160m-long hole with twohorizontal curves. The hole willalso be used for rock fissuregrouting to treat a known faultzone. ■ Contact:

[email protected]

R&D

Project debutfor core barrel

> Intrafor’s investment in

equipment continues to help

secure key contracts. A newKlemm 702-2 rig is installing 16 micro-piles for an elevatorinside Abu Dhabi’s PresidentialPalace. The rig is the only one inthe UAE that could gain accesswithout extensive demolition. In Hong Kong, Intrafor’sacquisition of a third new trenchcutter is helping reinforce itsposition as a leader in specialfoundations. Its new BauerCutter MC64/BC40 is already atwork on the Express Rail Link. ■Contact: sebastien.frebourg@vsl-

intrafor.com - [email protected]

Intrafor

Strategic equipment


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> China’s first use of the VSL

AF anchorage is taking place aspart of containmentconstruction projects. TGE GasEngineering of Germanyawarded VSL Hong Kong thework as post-tensioningspecialist on the NingboEthylene Tank and Zhejiang LNGTerminal projects, based onVSL’s reputation on previousLNG projects in China. TheNingbo tank, which has acapacity of 30,000m3, will usethe AF anchorage at the bottomof the vertical tendons. TheZhejiang project requires theconstruction of three tanks of160,000m3 capacity, using 1,496tof strand. Experienced civilcontractor China NuclearHuaxing Construction Companyis building the tanks and haspreviously worked with VSL onmore than 70% of itscontainment projects. ■ Contact:

[email protected]

> Intrafor has secured a major

contract to construct one of themost challenging sections of theMTR’s new Express Rail Link(XRL). The work forms asignificant part of Contract 820,which is being carried out by aDragages-Bouygues joint

> VSL India has recently won a

contract in northern India for100,200m2 of VSoL® polymericreinforcement on the Panipat-Jalandhar stretch of National

VSoL®

Polymeric production drive

Tanks

AF arrives in China

Foundations

Challengingwin on XRL

Diaphragm walls

Patented solution> Use of a new patented “soft

milled joint” developed by

Intrafor has avoided the need forextensive concrete cuttingbetween panels on a 91m-deepdiaphragm wall shaft as part ofHong Kong’s HATS project. Theshaft diameter of just 12.3mmakes the excavation works verychallenging. Trapezoidal blocksmade of lightweight precastconcrete replace the same volumeof hard concrete and create a softspot to ease the milling of paneljoints. The main contractor willbegin excavation down to the toefollowing panel completion,grouting and testing. Quality is of prime importance as the fullheight of the diaphragm wall willbe exposed. ■ Contact:

[email protected]

venture. The section passesunder a densely populated andheavily piled area wherechallenges include avoidingcausing any settlement.Intrafor’s responsibilitiesencompass foundations, groundtreatment and diaphragm wallshaft work. Over 100 personnelwill be deployed and two cutterswill be mobilized for thischallenging project. ■ Contact:

[email protected]

Highway No. 1. SOMA Enterprisesawarded VSL a turnkey contractfor the design, casting, erectionand supervision of VSoL® wallsfor a 57km section. The 2m by1.5m panels for the 13 monthcontract are to be cast at therate of 190 a day to supply the 25 structures, which have amaximum height of 9.5m. ■Contact: [email protected]


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COVER STORY


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BUSINESS DEVELOPMENT

Abu Dhabi: The new place to be?

Is Abu Dhabi the leading property investment and

construction destination in the UAE? As a matter

of fact, Abu Dhabi is forging ahead with major

long-term construction initiatives as part of an

ambitious 20-year regional development plan,

despite the global economic downturn. VSL is

forging ahead too, by providing technical added

value to its clients through all-inclusive design &

build packages.


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COVER STORY

B U S I N E S S D E V E L O P M E N T

Farsakh, General Manager at DutcoBalfour Beatty puts it: “We areproud of what we have achieved,proud of what we do. Our aim is toalways come up with better ideas.We have a quality approach. At theend of the day, you are as good asyour weakest link. That’s why wework with the best suppliers thatshare our values; there is no roomfor errors.” To provide what is bestfor the project and the client, VSL’steams of specialists, engineers andproject managers work withconsultants and contractors fromthe early project stage onwards.VSL’s capacity to provide expertconsultancy and alternativesolutions very often makes thedifference and its reputation as aspecialist civil works company goesway beyond local markets. “To winwork, we need to undertake valueengineering, offer alternatives, becost-conscious. We like to work veryclosely with competent companieslike VSL from the tender stage,because with companies like VSL wecan think out of the box and are, inthe end, in a win-win situation.”

VSL provides skilled and trainedstaff and construction specialists forall project stages. New methods,new equipment and new materialsare benchmarked and dedicatedteams tackle any challenges and

together.” Not only is there pastcollaboration, but also trust. “Weknow that if we go with VSL, weshould succeed together.”Generally speaking, a subcontractoron fast-track projects needs to bereliable, in all aspects. Partnershipsneed to be made with organisationsthat the client can rely on. “We needto work with someone we can counton - reliable in all senses of theword, flexible, professional, timely,quality-wise, not “claim minded”,everything.” This includes the abilityto work out of sequence assometimes things need to be donefaster than originally planned. “Weexpect our subcontractors to adapt.I don’t see VSL as a potential risk inany way on this project. I do notmake the decision, but when itcomes to senior management thereare some names that giveconfidence.”

Quality approachWhen the global downturn reachedthe shores of the UAE in 2008, all ofthe major players in the market hadto resize to adjust to the newrealities. Not only did contractorsand consultants have to becomemore selective in terms of theirprojects and partners, but they alsoneeded to feel confident about theirpartners and to be more proactive intheir business approach. As Wail A.

Post-tensioning is used in 90%of the bridges and 80% of thebuildings in the UAE1. As a

consequence of the global crisis,most infrastructure budgets havebeen trimmed and the financialviability of many projects is beingchallenged. Both public and privateowners are keen to re-examinetheir projects in order to ensure thatthey remain viable. The first effect ofthis situation has been that thetraditional post-tensioning supplymarket has become morecompetitive. As a renownedspecialist contractor, VSL is earningits share of these projects thanks toits 50 years of experience in post-tensioning and to having had apresence in the UAE for more than15 years. Its portfolio is extensive,covering supply and installationpackages for post-tensioning, staysand soil-wall systems as well asheavy lifting services, repairs andstrengthening. By having a proactiveattitude and providing technicaladded value to clients through itsservices and all-inclusive designand build packages, VSL MiddleEast stands out as a key partner inthe region’s bridge design andconstruction market, achievingsome major commercial successesin 2010.

But what makes a main contractorchoose VSL? “You start discussionwith potential subcontractors andafter a few weeks you only havethree or four serious candidatesleft,” explains François Springuel,Project Manager at SixConstruct-Samsung JV for the ClevelandClinic’s car park. “These candidatesgave us the confidence that they willdo it, and their names are very wellknown.” Then comes discussion ofthe contractual details and otheraspects before, finally, a decision istaken. “SixConstruct and VSL knoweach other, have a good experience

1 Construction Week magazine, edition 13-19 March 2010, pages 22ff


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technical issues from the project’soutset. The ability to come up withsolutions for any type of project andapplication is enshrined within VSL’scompany values.

Better solutionsVSL and Taisei have workedtogether on some very importantprojects in recent years, such asRas Al Khor 5, Gateway,Waterhomes and Downtown JebelAli. “We work together from thevery early stages of a project andlook for alternative solutions tobetter serve our client,” commentsKatsumi Tamura, General Managerin the civil engineering departmentof Taisei Corporation’s Dubai offices.“We are a general contractor andVSL is a very professional specialistin post-tensioning and precastconstruction, looking forward to newchallenges.” The need to explorecreative solutions is important in amarket like Abu Dhabi, which is verytough and has tough competition.Local construction companies havea very aggressive market approach.

Let’s take a “walk” to visit a number of VSLprojects from the past year, spread across thecapital. The city of Abu Dhabi had been carefullyand cautiously developed over 30 years;however, the pace increased dramatically inearly 2005 with the announcement of the firstmajor new development at Al Raha Beach andthe start of construction soon afterwards.

The New Islands The Emirate of Abu Dhabi, whose capital city isitself on an island, hasn’t needed to engage landreclamation as it has no shortage of shoreline andhas hundreds of natural islands to develop. Thereare now several “new” island developmentsongoing in Abu Dhabi and VSL Middle East isinvolved in almost all of them in some way, as youwill find out.

Yas Island and Saddiyat Island

Some 20km before reaching the Maqta Bridge atthe Abu Dhabi city gateway, a new interchangeleads to Yas Island and onto the Shahamma-Saddiyat Freeway. Yas Island is well known toFormula One fans as the final race in the F1calendar and the Yas Mariana circuit opened inOctober 2009. VSL has been heavily involved inthe main access infrastructure works on theisland, working for the main contractor SixCoand its client Aldar on two large bridgepackages involving 3,000t of post-tensioning aswell as over 90,000m2 of mechanically stabilisedearth (MSE) walls. If we continue along the freeway towardsSaddiyat Island, we cross two bridges where VSLhas completed 21,000m2 of MSE walls for arecently opened bridge built by Taisei. Thefreeway’s final section also features 1,850t ofVSL post tensioning and 9,500m2 of MSE wallsfor bridges and ramps constructed by Leightonfor TDIC. The most amazing feature of the 10-lane 27km-long freeway is the fast-trackconstruction period of just over 18 months,especially given the large amount of bridge androadworks over its complete length.

Al Reem City of Lights

As you enter Abu Dhabi city and join theCorniche from the new 10-lane Sheikh KhalifaBridge, you are at an ideal vantage point to seethe scale of development in the city and on itsislands.

By far the largest is Al Reem Island, where VSLhas recently completed the post-tensioningworks on one of the island’s first towers. Atpresent VSL is working on the post-tensionedslabs for two large projects for the developerTamouh. Towers of 61 and 41 storeys are beingbuilt by main contractor China State Hong Kong.Close by, VSL is also working on two of the fivetowers being built by main contractor SKEngineering & Construction and NamkangEngineering & Construction J.V . Both projectsare progressing at a fast pace, rising on averageone level every week.

Al Sowwah Island - The Rosewood Hotel

The striking Rosewood Hotel on the adjacentisland of Al Sowwah is being constructed byACC, which has in turn awarded VSL Middle Eastthe design, supply and supervision work for thepost-tensioned slab beam system.

The Cleveland Clinic

Adjacent to the Rosewood Hotel, Cleveland ClinicAbu Dhabi will be a 360-bed facility on Al SowaIsland, just across from the Abu Dhabi Mall. Oneof the clinic’s main objectives is to meet theneeds of patients who currently have to travelabroad for treatment. Work started in March2010 and the clinic is scheduled for opening aftermerely 36 months. VSL is in charge of the PTslabs and beams, casting the first beams at theend of November 2010, as the sub-contractor forthe Six Construct-Samsung JV. As we now travel along the wide expanse of AbuDhabi’s new Corniche, we pass Capital Plaza - alsobeing constructed by ACC – which consists of fivetowers varying from 38 to 52 storeys on a singlepodium. VSL recently completed the post-tensioningworks involving transfer beams in the podium andpost-tensioned beams at each floor level. Still further along the corniche is the aptly namedLandmark Tower, rising high above its neighbours

Abu Dhabi: visit our sites!

>


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at over 330m, with 72 storeys. Here VSL’s scopeof work includes post-tensioned slabs andtransfer walls for the main contractor, a jointventure of Al Habtoor Engineering and CCC.Continuing to the west, we find the four towersof the Khalidiya Palace, where VSL has recentlycompleted the post-tensioned flat slabs formain contractor Nurol and has just commencedon Nurol’s adjacent Bab al Qasar which includesa 375-room luxury hotel and a 234-unit servicedapartment over its 32 floors, 5 podium levelswith swimming pools and hotel facilities, and 4 basement floors and will have a total closedarea of 155,000m².

ADNEC Capital Gate Tower

You cannot fail to miss the next landmark on thehorizon, the ADNEC (Abu Dhabi NationalExhibition Centre) Capital Gate Tower, which hasrecently reached its full height of over 160m.The iconic tower is already well known as Abu

Dhabi’s leaning tower and is inclined at anincredible 18° - which is 14° more than Pisa’sfamous tower. The core slants in the oppositedirection to the lean of the building,straightening as it grows in a design that hasnever been attempted anywhere before. It wasdesigned by RMJM and the main contractor is Al Habtoor Engineering. VSL designed, suppliedand installed vertical bar tendons in the lowersections of the core and multi-strand verticaltendons higher up.

COVER STORY


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A few streets across on the east coast, Intraforhas just completed a 16m deep, 3,500m3

diaphragm wall project at the EasternMangroves. The client for the development isTDIC, with Leighton as main contractor and ASTas the subcontractor and Intrafor’s client. The Maqta Bridge is the oldest route onto AbuDhabi Island and just to its east is the new SheikZayed Bridge. For several years, VSL has beeninvolved as subcontractor to Archirodon-SixCo

for a variety of the specialist aspects such asMSE walls, post-tensioning, heavy lifting andthe supply and installation of the stays for thisincredibly complex 842m-long structure. In late2009, together with the main contractor, VSL erected the secondary arches followed bythe main arches, of which the heaviest sectionweighed in at 600t.

Heading back, North Est, we reach one of VSLMiddle East’s largest groups of projects to date.

Al Raha Beach

The Al Raha Beach development is a beachfrontproject being built along the Abu Dhabi-Dubaihighway, opposite Al Raha Gardens. Developedby Aldar, Al Raha Beach will accommodate >


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COVER STORY


“We, at Taisei, can do any workrequired on a construction site. Butwe work with sub-contractors fromwhom we expect know-how,experience, good solutions andclose co-operation. Together wecan come up with better solutionsand we always look for synergies.”

Transfer of knowledgeTo perform as a preferredconstruction partner, VSL isconstantly innovating andimplementing new work methods.Proper training is a vital first step insharing knowledge and inemphasising that safety is of utmostimportance for VSL and its clients.VSL Middle East’s training centre inDubai was created to spread theVSL Academy’s knowledge and bestpractices. VSL’s training premisesallow for the installation of practicalequipment and there is also adedicated classroom for moretheoretical lessons taught by asenior project manager with longexperience in training. Externaltrainers cover non-technical topicssuch as internal auditing, first aid oroffice software. The trainingmanager regularly goes out to sitesto assess the courses’ efficiency.Competence cards are issued andknowledge transfer is organised inthree steps: training, assessmentand re-training, if necessary. Inaddition, the training centreorganises sessions giving clients an“Introduction to VSL systems” andthese are very much appreciated asthey help providing a better mutualunderstanding of procedures andrequirements.

Safety is the No. 1 priority “The challenge of projects in theregion is that you have to deliver ahigh quality project quickly,” saysMick Timmons, Project CommercialDirector of Al-Futtaim Carillion LLCon Al Muneera Project, Khor alRaha Precinct and Al Raha beachDevelopment, “At the end of the day,however, it all comes down tosafety. We are applying safety

standards and we are proud ofhaving achieved over 21 million manhours without a reportableaccident.” To make sure everyoneunderstands and follows this, VSLhas been involved - as has everyother subcontractor - in the differentactions needed to come up to UKstandards. This demanded a hugeamount of management input, but“the number one priority is safety.We can build a successful project,but need to be safe at all times.”

VSL’s actions are not limited toconstruction sites; safety is also aconcern for office staff. VSL MiddleEast picks up and drops off stafftravelling to and from work. One ofthe items highlighted in an internalinquiry was that members of staffare sometimes concerned by thedriving standards. As a result, VSLimplemented a tracking system inSeptember 2010 covering allcompany vehicles. It givesinformation about the routes, traveltimes and speed at all times.Positive effects on the drivers’behaviour showed immediately. The expected results are improvedsafety, fewer accidents, fewerspeeding tickets, less exposure torisky situations and a better use ofresources with better planning andimproved travel times.

“Safety is a big issue, like for allprofessionals such as VSL,”confirms François Springuel, fromSixConstruct-Samsung JV. Asreputable international companies,VSL and SixConstruct-Samsung JVhave the same high safetystandards. More and more overrecent years, a dramatic change inmentality can be noted where safetyis concerned. “It was difficult…”recalls François Springuel. At DutcoBalfour Beatty too, safety is ofutmost priority at all times. “Ourcompany initiative is to achieve zeroharm by 2012 - all initiatives areaimed at making the sites as safeas the office environment,” saysWail A. Farsakh.

120,000 residents in high-rise towers and low-rise developments. The district will serve as anew gateway to the city and is being built in 11 residential and commercial precincts, eachwith its own distinct personality and appeal. VSL has been working on PT building projects atAl Raha Beach for some years and the latestproject - Al Muneera, awarded in 2009 - willbring the total area of post-tensioned slabscarried out by VSL to almost 1,000,000m2 uponcompletion. On the civil works side, VSL has also been keptbusy from late 2008 until today, working on atotal of 21 bridges, requiring 1,900t of tendonsas well as bearings and stress bars.

VIP terminal roof lifting, Abu Dhabi Airport

Standing next to the existing Abu Dhabi EmiriTerminal, the new Presidential Flight StateGuest Terminal will play an active role for thecity. The current economic outlook means thatcontractors require cost-effective solutions builtto ever tighter schedules and VSL responded bycoming up with a challenging method to lift theVIP reception hall’s entire roof structure in onego. The 330t steel roof comprises a 65m by 85mspace frame with four main steel trusses on top.It was assembled in record time at ground leveland smoothly lifted by 20m into its finalposition.

Our journey today ends here but Abu Dhabi hasactive development plans for a metro system,nuclear plants, museums, major bridges tomany of the remaining islands, a new highway tothe Saudi border and the “green” Masdar city…and many more schemes on a list that willcontinue to grow. ■


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Growing strengthThe mushrooming growth in theMiddle East throughout the lastdecade has created a potentialmarket for structural upgradingrepair work. Structural PreservationMiddle East (SPME) - a joint venturebetween VSL Middle East andStructural Preservation - uses thelatest technologies to developinnovative strategies to upgrade andrepair, restore and increase theload-carrying capacity of concrete,steel, masonry and timberstructures. It offers a unique blendof design support, contracting,systems and materials, making thecompany the leader in thestrengthening of existing structures.The goals of owners, engineers andgeneral contractors are typically thesame: to deliver a safe, efficient andeconomical solution, whether thestructure requiring strengthening isunder construction or in service.SPME assists project teams in thedevelopment of comprehensivesolutions, providing structuralrepair, strengthening and corrosionprevention for industrial andcommercial structures throughoutthe Middle East. Strengtheningprojects are always critical; SPME’steams are able to mobilise at shortnotice. “We can’t afford a learningcurve as the lead time for ourprojects can be as little as twodays,” says Muneer M. Merchant,SPME’s Manager. “We need to comeup with solutions and be ready tostart work almost immediately.”SPME has no less than 65permanent staff and is nowexpanding its presence in the AbuDhabi market.

Best for barsVSL has been marketing bars forthe construction industry since theearly 1970s and offers an extensiverange of products complying withinternational standards. To providethe best quality in the shortestpossible time and VSL Middle Easthas launched a 50/50 joint venturewith Stahlwerke Annahütte, theworld’s leading manufacturer of

applications on the Dafah–Shishroad and tunnel and the Abu DhabiSalam street tunnel.Abu Dhabi has already launched alarge number of major projects andhas plans in place to launch amultitude of projects throughout thecoming years involving residentialdevelopments, luxury touristaccommodation, shopping malls,huge infrastructure projects (roads,public transportation and bridges),the extension of the airport and thedevelopment of the surroundingislands. It is up to VSL to identify thepotential of these projects and tobecome involved from thebeginning. ■

SAS threadbar systems. “Ourpremises here in the UAE allow usto reduce the lead time to aminimum because we havesufficient storage space to carrystock,” says Shemi P.S., SalesManager for bar systems. “We alsohave all the necessary equipment,such as automated indutrial cuttingequipment to crop the bars to therequired length as well as acustomised handling equipment tohandle the large diameter bars.”SAS bars are of high quality and canbe re-used; they are self-cleaningfor maximum efficiency and can be

Half of the major projects currentlybeing undertaken in the UAE are locatedin Abu Dhabi, which is a very wealthyregion. It has roughly 9% of the world’stotal oil reserves, 4% of the total gassupply and one of the largest sovereignwealth funds anywhere. Abu Dhabi hasalways been cautious in taking on debtand has set up a plan running throughto 2030, involving long-term projectinitiatives that include development ofthe surrounding islands. The projectsinclude major infrastructure schemessuch as roads, railways, airports, ports,and bridges.

provided with different degrees ofcorrosion protection depending onthe specifications. The range ofproducts and applications isextensive: from rock anchors orbolts for geotechnical applicationsto temporary or permanent post-tensioning applications and marineprojects. “Form-ties are sold overthe counter, the ability to stockselected bar diameters and gradesmakes VSL highly competitive interms of price and lead times,”Shemi P.S. concludes. Some recentapplications include work in themarine environment of Dubaidrydocks, post-tensioning for DohaSports City, geotechnical


> Varela Bridge near Aveiro has

reopened with a wider deck aftera complex rehabilitation andstrengthening project designed byA2P and carried out by Obrecol.The 308m-long curved deckcrosses the Ovar Channel with ten30.8m-long spans. The originalbridge had a 6.5m-wide cross-section with a concrete slabsupported on six T-shaped beams.Increasing the width to 12.5minvolved installing identical precastbeams on either side, connectedtransversally by steel beams. VSL Portugal used bars andexternal post-tensioning to enlargeand strengthen the pier heads.VSL’s scope also included liftingoperations, concrete repairs andthe supply of new pot bearings. ■Contact: [email protected]

> iGuzzini Illuminazione Spain has

built an iconic new headquarters

building near Barcelona. Thestructure’s singular design takesthe form of a slightly deformedsphere emerging from the ground.All the floors are suspended from acentral group of columns in thecentre of the sphere.VSL hasprovided technical assistance andsupplied a large quantity of its75mm-diameter Y1035 bar for thefloor suspension system. ■Contact: [email protected]

Portugal

Deck doubling

Spain

Sphericalsuspension

Spain

High-speedVSoL®

> CCT Stronghold has completed

the design and construction of a150m-long VSoL® wall for a newhigh-speed rail line from Madridto France. The 7.8km section,100km north of Barcelona,includes viaducts up to 245m longand a 1.75km tunnel. Facing

elements were formed fromconcrete panels, using polymericreinforcement to avoid straycurrents. Erection of the 12m-highwall was completed in record timewith total geometric accuracy. ■Contact: [email protected]

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> The 236m-long superstructure

of the Porcia Bridge in Asturias,north-west Spain has beenlaunched successfully by CTTStronghold. Assembly took placeon temporary steel supports. Thebridge was jacked up with thestandard VSS skidding system toensure the correct alignment for asmooth downhill launch of theentire steel and concrete deck

> A delicate operation to remove

three TBM sections weighing up to120t from a new water tunnelbeing built at Barxeta has beencompleted by CTT Stronghold. A 7.5m-wide cave was created togive room to load the sections,which were up to 5m in diameter.VSL pulled each piece with a 70t cable hydraulic unit and thenjacked it up 1.5m with four 90t climbing jacks so that atransport platform could bereversed underneath. Once loaded,it could then be driven out. ■ Contact: [email protected]

> Two complex silo projects have

been carried out by CTT

Stronghold. A new 120m-high silowith an internal multi-cellconfiguration has been reinforcedusing unbonded NSM (NearSurface Mounted) post-tensioningto increase the shear response ofthe internal walls by 70%. Thetechnique involves precision

Spain

Precision sawingSpain

TBM extraction

Spain

Downhilllaunch

structure. The 1,750t launchacross three intermediate piers(80m main span) was done in twophases in a pushing/pullingprocedure using the VSS 500skidding system and the SLU. Itsmain advantage was that the VSL

skidshoes included double-actingvertical hydraulic jacks, whichmeant that VSL could control andcorrect the loads and levelsthroughout the launch. ■ Contact:

[email protected]

sawing to create grooves, togetherwith drilling, anchorageplacement, controlled tensioningand the use of non-shrinkingmortar. An existing 47m-high silowas patch-repaired and providedwith external post-tensioning andwaterproof mortar protection. ■Contact: [email protected]

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> Barcelona’s new Design Hub by

architect MBM will be a centre for

promoting design excellence. Itsthree main areas have different usesand structural demands. VSL’sinvolvement has covered post-tensioning and design assistance tomain contractor Acciona-Copcisa JV

> CTT Stronghold has

successfully carried out a second

drill-head replacement for atunnel boring machine buildingBarcelona Underground Line 9. Thework at the Guinardó shaft followedmanoeuvres at Habaneras (see VSLNews 2009/2). Geometricdifferences between the two sitesled VSL to design a steel structureto allow the reuse of the hydraulicjacks from Habaneras. Equipmentwas further optimised by the use oflarger VSS 500t skiddingequipment to avoid the need for thesubstantial steel beams required at

Spain

Second TBMsuccess

Spain

Tailored design

Habaneras. Once again, the mostimportant factor in the operation’ssuccess was the achievement ofaccuracy to the millimetre in threedimensions. ■ Contact:

[email protected]

and consultant Boma. Key aspectsinclude Block 2’s two unbalancedsteel cantilevers, which are up to35m long. VSL’s Bondtech® systemwas chosen for the slabs of thecentral core that caters for thecantilever loads. CS crossed tendonswithstand the high tensile stresses

in the walls. Block 3 also has anunusual feature: a double-height4,000m2 slab with a 16m by 19.4mcolumn layout. VSL’s solutionconsists of a 750mm flat concretewaffle slab, providing an extremelyhigh stiffness to self-weight ratio.■ Contact: [email protected]

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SITE INSIGHTS


Mexico

Up to 20%savings> Meridiano Tower is a new icon

in the business centre of

Monterrey City in Nuevo Leon,Mexico. The 23-storey tower wasbuilt by one of Monterrey’s mostimportant construction companiesand the construction works tookabout 12 months. VSL developedthe project’s structural design aswell as supplying and installing thepost-tensioning materials. Use ofVSL’s post-tensioned solutioninstead of traditionalreinforcement achieved a 10% costsaving for the slabs and a 20%saving for the foundations. In total,the 27,600m2 of post-tensionedslabs required about 70t of 0.5”(12.7mm) strand. VSL’s scope inthe foundation constructioninvolved the provision of 26t ofstrand. ■ Contact:

[email protected]

> CTT Stronghold and VSL

Switzerland have successfully

lifted the 1,325t roof structure of El Prat Airport’s huge new 25m-high maintenance hangar,measuring 155.5m by 87.5m at anaverage speed of 4m/h. VSL began working with Iberia andAssad Desarrollo well in advance ofthe installation. Appointedcontractor Cobra and VSL found that

Spain

Absolute zero

Spain

From ground to roof

> New parking arrangements

required the repositioning of a

first-floor column while the eightfloors above remained in use andfully loaded. CTT Strongholdcarried out the successful high-precision reverse beam transfer.The primary constraint of thedesign was a requirement for"absolute zero displacement" to

avoid cracks in the façade. Thiswas achieved using active jacking,post-tensioning and non-shrinkingself-compacting concrete.Operations included lifting and loadtransfer using a new steelstructure, controlled demolition andinstallation of a new active beamusing post-tensioned beam transfer.■ Contact: [email protected]

the best solution was to build theroof at ground level and lift it in asingle movement. VSL proposeddouble and balanced lifting points toavoid the need for temporaryreinforcement for the final columns.The 14 strand lifting units (SLU) ofdifferent capacities were balancedwith another 14 SLUs for a retainingforce of 850t. ■ Contact:

[email protected]

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> VSL CZ and VSL Heavy Lifting

recently lifted the 1,500t roof of amulti-purpose sports hall in Sofia.The roof was assembled at a 19m-high level and lifted to its finalposition at 30.5m. VSL’s in-houseBravo control system monitoredlifting forces and ensured that theheight difference between theeight lifting points was kept withinthe 25mm tolerance. The operationwas one of the first of its kind inBulgaria. ■ Contact: [email protected]

> The 88.5m-span Aare River

Bridge in the Swiss city of Oltenwill lead directly into a tunnel andthe designers have opted for anextradosed structure anchored onone side only to the tunnel portal.The 2.6m-high main girders aresuspended on prestressed"concrete sails” and anchored sothat the tunnel becomes a load-bearing component of the bridge.Challenges for VSL include thecongested arrangement of tendonswithin the sails, the requirementfor a deviation tube at the top ofthe sails and fixing the sailtendons at the tunnel walls. ■Contact: [email protected]

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SITE INSIGHTS

> VSL Switzerland has embedded

its first anchorages for theRussian Federation’s expandingnuclear power market. Theanchorages are for the innercontainment of the first block ofthe LAES-2 Nuclear Power Plant inSosnovyi Bor. The VVER-1000 plantis being built by OAO Metrostroyfor Atomenergoprojekt SaintPetersburg, acting as designer and

Russia

Nuclear firstgeneral contractor. VSL issupplying NC 6-55 unbonded post-tensioning, which is a greased andsheathed system that complieswith the latest nuclearrequirements. The project includes 50 vertical tendons and 76 horizontal hoop tendons foreach block, requiring a total ofabout 1,400t of strand. ■ Contact:

[email protected]

> Various VSL PT systems are

being used for a 960m-longviaduct on the Nitra – BanskaBystrica section of the R1expressway. Bridge 205 has beendesigned by Stráský, Hustý apartneři and the contractor is theSlovakia branch of Eurovia CS. Theconcrete bridge has typical spansof 69m and its superstructureconsists of a single box girder withoverhangs supported by precaststruts. It uses internal and externalVSL post-tensioning systems. The top slab is transversally post-tensioned using the VSL S 6-4bonded slab system while the VSLthread bar system is implementedto fix the struts prior deck casting.■ Contact: [email protected]

Bulgaria

Weight liftingevent

Slovakia

Viaductvariety

Switzerland

Concretesails


USA

Proactiveinspections

> VSL’s Washington D.C. office

recently carried out an

emergency repair to the OneidaRiver Bridge in New York state.The project, which involvedstrengthening with external post-tensioning, was prompted byinvestigations that showedsignificant corrosion on the fasciagirders of this first-generation

> Oklahoma Department of

Transportation has awarded VSL’sWashington D.C. office a contract toinspect 18 post-tensioned bridgesin a proactive measure to ensurelong-term durability. The VSL teamis working with URS and SivaCorrosion Services on the project,which represents the largestnumber of bridges inspected byVSL under a single contract.Inspections began in mid-Marchand involve the use of groundpenetration radar and borescopeequipment to determine thecondition of the tendons. Thestructures include Oklahoma’soldest precast segmental bridge,the signature Sailboat Bridge overthe Grand O'Lake of the Cherokees.■ Contact: [email protected]

> VSL's Civil Projects Team has

recently secured contracts forseveral key bridge projects,including the New Mississippi RiverBridge, which will become theUSA’s third-longest cable-stayedbridge. VSL will supply 1,142t ofstay cables together with 136friction dampers and 425t of post-tensioning for the bridge, which isin St Louis, Missouri. VSL isworking with Figg BridgeDevelopers on the new SouthNorfolk Jordan Bridge inChesapeake, Virginia, where it issupplying 702t of post-tensioningfor the precast segmentalconstruction. Archer-WesternContractors selected VSL to furnish360t of post-tensioning and providea leased set of VSL modular formtravellers for two new bridges overthe Colorado River in Marble Falls,Texas. ■ Contact: [email protected]

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Poland

Airport interchange

USA

Emergency repairs

> VSL has completed the first

cable-stayed project to use its newSSI 2000 V-saddle technology. TheV-saddle represents the latestdevelopment in stay cable systemsand simplifies pylon design. TheM43 Bridge in southern Hungarycrosses the River Tisza with a180m-long main span supported bytwo pylons. Hidepito has built thebridge, which has a total of 64 SSI2000 stays of size 6-37. ■ Contact:

[email protected]

Hungary

V-saddleenters use

USA

Multiplesuccesses

> VSL Poland is supplying and

installing the post-tensioning

systems for the three viaducts ofWarsaw’s Okecie Interchange.Construction is being carried outby Karmar, a subsidiary ofBouygues International Buildingdivision. This interchange willprovide access from the ChopinWarsaw Airport. The viaductbeams are stressed by cables oftype 19L15 and 22L15. Post-tensioning work on the firstviaduct started during the summerand VSL Poland’s work is due forcompletion by the end of the year.■ Contact: [email protected]

splice-girder bridge, built morethan 50 years ago. VSL designedthe retrofit as well as providedmaterials, equipment, andtechnical assistance on site. Workbegan in mid-March and tookapproximately eight weeks tocomplete, with VSL working withlocal contractor Slate Hill. ■Contact: [email protected]


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SITE INSIGHTS

Malaysia

Johor approaches completion> A 1.7km-long cable stayed

bridge over the Johor River delta isexpected to be opened to traffic inearly 2011. The Sungei Johor Cable-Stayed Bridge has a 500m mainspan flanked by 137m side spansand 484m approaches consisting ofconcrete post-tensioned three-cell

> VSL Philippines has been

working with Citra Metro Manila

Tollways Corporation and maincontractor DM Consunji Inc. on amajor project designed to reducecongestion in Metro Manila. SouthMetro Manila Skyway Stage 2project is a six-lane, 7kmexpressway that will double roadcapacity. VSL is involved in thepost-tensioning of 104 pier heads and columns as well as 1,832 precast girders. The workfollows on from VSL’s involvementin the first stage of the project,which opened in 1999. ■ Contact:

[email protected]

Philippines

Skyway return

box-girders. Both approaches wereconstructed using a VSL-designedincremental launching method,which was supplied and operated byVSL Malaysia. The scope of worksalso included the supply andinstallation of post-tensioning forthe concrete deck. In addition, VSL

supplied and installed the bridge’s84 stays, which use the SSI 2000system. The 7.85m-long steelcomposite segments for the sideand main spans were delivered bybarge and erected using a cranemounted on the bridge. ■Contact: [email protected]


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Rail quadruplication

> Medium Term Link is a 1km

elevated bridge project designedto connect the Malaysia-Singapore

> VSL Australia provided a full

design and supply package for 12 different VSoL® Retained EarthWalls for one of Sydney’s largestrail infrastructure projects. Thewalls stand up to 5m high and havea total panel area of 3,660m2. TheKingsgrove to RevesbyQuadruplication (K2RQ) Project

Causeway with new customs,immigration and quarantinefacilities. VSL worked in jointventure with a local contractor tocast and erect 476 precast boxgirder segments for the bridgesuperstructure. Erection of thetwin carriageways was by the freecantilever method using anoverhead launching gantry. The 23cantilevers had spans ranging from34m to 44m. Construction logisticswere very challenging as the bridgepasses over major water pipelinesand existing road and rail traffic. ■Contact: [email protected]

will provide two additional tracksto separate local and expressservices operating on the EastHills Line. It is part of the NSWGovernment’s Rail Clearwaysproject, designed to improvecapacity and reliability on the CityRail network. ■ Contact:

[email protected]

Malaysia

476 segments Complex ground anchors. VSL

was appointed by VEC Thiess JV

to drill, supply and install

14 permanent anchors on the

Brighton Bypass project in Hobart,

Tasmania. VSL was chosen for its

ability to meet the project’s

complex technical constraints.

Careful planning. Shanghai

Power Engineering &

Construction awarded VSL the

PT work on the 50,000m3 Ningxia

LNG tank project. A two-month

winter shutdown on the worksite

required VSL to plan the works

carefully to accommodate

temperature constraints and meet

time limitation between strand

installation and grouting phases.

Centennial challenges. The

University of Hong Kong’s new

Centennial Campus extends

constructions over a former

reservoir. VSL’s scope involved

drilling, supply, installation and

stressing of 200 temporary ground

anchors to hold back sheet piles

during phased excavation works.

Challenges included unpredictable

ground conditions.

VSoL® double. VSL Australia was

recently awarded a contract to

design and supply retained earth

walls for the Banora Point upgrade

project. The contract involves

11,000m2 of patterned VSoL® walls

up to 12m high as well as 2,400m2

of temporary VSoL® walls.

Windy city. VSL provided an

engineering solution to heavy lift

the preassembled retractable

roof structure of the 14,000-seat

Perth Arena, in Australia, from

the ground to its final position,

while avoiding any issues arising

from local strong seasonal winds.

Brunei bridges. Bridge repair

and strengthening work on the

Brunei Muara District Phase 1

contract involves rehabilitation of

24 different bridge types. VSL’s

scope on the 12-month contract

covers concrete assessment,

repair and protection as well as a

bridge deck replacement.

N O T E P A D


> The use of high-strength thread

bars as proposed by VSL’s TechnicalCentre Asia/Australia has proved aneffective solution for counteractingexpected ground heave duringconstruction of Singapore’s 5km-long Marina Coastal Expressway.Using the Y950/1050 steel bars astension reinforcement in thetemporary tie-down piles resultedin lighter and less congested

> VSL Australia is achieving a

consistent average cycle time ofeight segments a night in a seven-hour erection window for a majorroundabout upgrade at Brisbaneairport. The project involves theconstruction of a 641m-longsegmental balanced cantileverbridge. Segments are being erectedby a VSL-designed segment lifter atone end and a 280t crawler crane atthe other. Being able to erectsegments on both decks beforerelocating the lifter has hadsignificant programme benefits.The segment lifter has alsominimised traffic impact as it doesnot require set-up time during thenightshift. The main contractor isThiess John Holland JV. ■ Contact:

[email protected]

> Section 4A of the Geelong Ring

Road involves the construction of2.5km of four-lane, dual-carriageway freeway from PrincesHighway to the junction ofAnglesea Road and Hams Road.VSL Australia was appointed byFulton Hogan to supply innovativeand high-quality precastcrossheads and match-cast piersas well as supplying and installingstress bars. One of the majorhighlights of the project was the way in which the VSL team was able to store and load the 115t segments without the use ofcranes. ■ Contact: jmckenzie@vsl-

australia.com.au

Australia

No crane atGeelong

Australia

Both decks at once

Singapore

High-strength solution

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SITE INSIGHTS

reinforcement, which enabledeasier and faster constructiondespite the extra time required fortechnical approval. VSL BarSystems division - a joint venturebetween Stahlwerk Annahutte andVSL Singapore - completed the1,300t supply in June and a secondphase requiring similar quantitiesis expected to start in early 2011. ■Contact: [email protected]


> VSL has been awarded a

21-month contract for the design,supply and installation of 1,270t ofpost-tensioning for 350,000m2 ofthe Ramanujan IT Park in Chennai.Partial stressing is being used toavoid early shrinkage cracks andto facilitate early formworkremoval. VSL is working as anominated sub-contractor on theproject, which is being constructedby an alliance of Tata Realty &Infrastructure, Leighton India andspecialist consultants. ■ Contact:

[email protected]

India

PT for IT

Hong Kong

Top trusses> VSL Australia has used

innovative edge forms to achieve aperfect slab finish on a contract todesign and build a 16,000 m3

concrete water tank. This tank ispart of Southern Sea WaterAlliance’s Binningup DesalinationPlant project and has a 2,800m2

post-tensioned slab cast in twopours. The slab was formed usinginnovative hybrid steel and plyedge forms, which resulted in acrack-free surface finish. Sixtyprecast panels were manufacturedat VSL’s precast facility in Perth.Western Australia has been usingdesalination as a major publicwater source since 2006, when itopened the country’s first plant.

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VSL Australia has carried out anumber of other precast andinstallation projects on thestrength of its delivery of acomplete design and constructionpackage on the initial project,where it brought cost and timesavings through the use ofalternative design and innovativeengineering. ■ Contact:

[email protected]

> A joint venture of VSL Hong

Kong and Kaden is planning aheavy lift operation for June 2011to position the 1,600t central spanof the Crossing Bridge across HongKong’s Eastern Channel. The 55m-

long central span will be lifted froma barge using SLU 550 units andslid into position. Tight clearanceswill require meticulous monitoringof the tide levels. ■ Contact:

[email protected]

Australia

Perfect finish

Hong Kong

Tight clearances

> VSL Hong Kong has lifted six

‘mega trusses’ totalling 2,560t forHong Kong’s prestigious TamarDevelopment project. They willbecome a roof structure thatcontains three office levels andlinks the two wings that will formthe Central Government Complex.The trusses, which are 17m highand up to 58m long, were lifted byapproximately 100m in twooperations, each of three trusses.Target speed was 12.5m/h to allowcompletion of each lift in a singleday in compliance with noisepermits. ■ Contact: yw.yung@vsl-

intrafor.com


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VSL has developed a Grout void sensor that reduces the risk of

undetected defects when grouting post-tensioning tendons, ensuring

a high degree of durability.

GROUTING OPERATIONS

How to avoid voids?

anchorages cast into concreteboxes and the strands remainedunstressed. In total, 21 sensorswere installed at seven testingpoints. Three sensors at eachtesting point were arranged atvarious distances from the ductcentre to monitor the degree ofgrout filling.

The sensors monitored twodifferent parameters:- measurement during the

injection process to detectchanges in currentindicating how far theflowing grout hadreached;

- measurements takenimmediately after thecompletion of theinjection to determinethe passivatingproperties of thegrout filling and toconfirm thecomplete filling ofthe duct at theparticular locations.

The results of the passivationmeasurements were checked fivemonths after injection by visually

Poor grout quality, voids and thepresence of bleed water are allpotential risks in any structurethat uses post-tensioning. VSL has developed a grout void sensoraimed at reducing the risk ofundetected defects in the groutaround post-tensioning tendons sothat durability is ensured. VSL Grout void sensors can beinstalled at critical points alongthe tendon to monitor the groutingoperation and measure theproperties of the grout. This allowsimmediate corrective action to betaken if the specified criteria arenot being met.

The sensor has three electrodes -sensor, counter and reference - for the required electrochemicalpassivation measurements.Installation of multiple sensors ona tendon is very easy as the sensorcan simply be screwed into theduct and other fixings.

Successfully tested in the field A successful field test on a post-tensioning tendon equipped withVSL Grout void sensors has beencarried out using a full-scalemock-up erected at VSL’s workshopin Subingen, Switzerland. The testemployed sensors made by SGK(Swiss Society of CorrosionProtection) on behalf of VSL. A supporting frame was used toform a 40m-long 12-strand tendoninto an arch ready for injection.The tendon was equipped with VSL PT-Plus® plastic ducting andCS 2000 anchorages. The

inspecting the grouting at thetesting points. The resultsconfirmed that the sensors hadcorrectly detected complete fillingof the duct, presence of grout voidsof 2/10mm (depth/ length) anddefined the presence of bleedwater.

PerspectivesThe VSL patented Grout voidsensor can be used for detection ofincomplete filling during thegrouting process. Passivationmeasurements of the sensorsgenerally worked well in the full-scale test. The full-scale testprovided valuable indications forthe definition of the evaluationcriteria which can now be fine-tuned to address the needs of atypical project. The next step will

be to fabricateequipment designedfor use on site with

the aim ofconfirmingthe concepton a real

project. ■

R&D

Fig.1 The Grout Void Sensor used in the field test


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VSL has taken a step forward in the repairs market with the completion

of the highly complex project on a key motorway viaduct across

the Trancão valley, on the highway from Lisbon to Porto, Portugal.

REPAIR & STRENGTHENING

Seismic upgrade for historic viaduct

The deck runs across six longitudinal

beams, each of which is supported

directly on a concrete arch at mid-span

and inclined pillars.

FOCUS


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FOCUS

S E I S M I C U P G R A D E F O R H I S T O R I C V I A D U C T

created by the arches arestructurally independent, as thedeck between them is simplysupported with a movable bearingat one side.

A2P analysed the structuralbehaviour and concluded that thebridge could handle generalvertical and wind loads but that itwas not in a condition to assuresafety under today’s designstandard requirements. Indeed,seismic loads were not taken intoconsideration at the time when theviaduct was originally designed.The consultant found severalcritical deficiencies under today’sdesign standard requirements.

Motorists crossing the TrancãoRiver valley on the A1 Lisbon toPorto highway may not realise thata very distinctive structure liesbeneath them. The viaduct, whichhas a web of concrete arches, wasdesigned by António Franco eAbreu and Rui Correia and openedin 1959. It has remained in servicethroughout a recent major upgradethat has brought it up to today’sseismic requirements and given ita new lease of life.

Retrofit requiredThe retrofit project was designedby consultant A2P on behalf of theowner, Brisa. Soares da Costa wasthe main contractor responsiblefor the overall project and choseVSL Portugal as the specialist forthe complex tasks involved in theseismic strengthening as well asbearing and joint repairs, 1,200m2

of concrete work and 32,000m2 ofpainting.

The 290m-long viaduct has five57m-long spans, each with sixparallel arches. The deck’s 26.5m-wide slab runs across sixlongitudinal beams, each of whichis supported directly on a concretearch at mid-span and on additionalinclined pillars. The six parallelarches are also connectedtogether by transverse cylindricalconcrete beams. All the spans

AnalysisThe first problem that A2P foundwas related to structuraldisplacement under seismicloading. The lack of deckconnections between the simply-supported spans allowed differentbehaviour for each independentsection of the structure. Theconsultant also confirmed that theexpansion joints and bearings hadno capacity to accommodate anysignificant movements arising inextreme situations, such asadjacent beams moving out ofphase.

The second deficiency related tothe resistance capacity againstseismic loads. Analysis showedthat most of the structuralelements – i.e. piles, arches andtransverse beams - hadinsufficient resistance in the faceof seismic events of medium orhigh intensity.

The retrofit was designed to reducethe effects of seismic loads and itsmain objectives were to controldisplacements, increase thecapacity for resistance and improvethe ductility of the structure. Several solutions to these issueswere studied, such asstrengthening the whole structureor adding new elements, but thebest was the dissipation of seismic

In total 60 HDRB’s, 120 longitudinal and 30 transverse

dampers were installed for the base isolation

A combined system of base isolation

with a passive damping system.


N E W S N ° 2 - 2 0 1 0

29

energy and thus, the reduction ofeffects and displacements. So itwas decided to opt for a solutionthat would connect the wholestructure and to introduce a baseisolation completed by a passivedamping system.

Introduce base isolationThe load intensity is a function ofthe structure’s main frequency andalso of the damping effects. Baseisolation reduces the frequency tolevels where spectralaccelerations are lower and so lessdamaging to the structure. Viscous dampers underneath thebases of the arches have the effectof producing a significant increasein the equivalent damping and soreduce the acceleration. Introduction of base isolationinvolved the installation of high-damping rubber bearings at thebase of the arches, with viscousdampers in both the longitudinaland transversal directions. The

strengthening of the arch bases.Overall deformation was difficult topredict because of foundationmovements and other side effects,even though the displacementsarising from dead loads andtemperature were straightforwardto calculate.

Cutting the structure had the effectof releasing the deformations, theextent of which had to be taken intoaccount in ensuring the solution’saccuracy. The A1 is key highwayand so all operations had to becarried out while traffic continuedto operate normally.

Eliminate deck jointsThe retrofit solution reduced deckdisplacements and required theelimination of intermediateexpansion joints on the deck.

system was designed to achievedamping effects of 25% to 30%.

In total, 120 longitudinal and 30 transverse dampers wereinstalled, using two longitudinaldampers for each bearing as wellas transverse dampers betweenbearings. The system also has acut-out, which is calibrated tobreak under seismic loads whileallowing normal operational,temperature and wind loads.Additional steel devices were alsofitted to restrain transversedisplacements.

Install bearingsInstallation of the bearingsrequired cuts of 32cm to be madeat the base of the arches with thehelp of steel work and temporaryhydraulic jacks. This type ofoperation can cause significantchanges in the structure duringload transfer and so carefulmonitoring of the displacementswas required together with

High-strength bars were installedthrough the deck’s transversebeams at the existing expansionjoints and they were stressed inorder to connect the longitudinalbeams of the contiguous decks. In addition, the transversecylindrical beams were reinforcedwith 1,750m2 of CFRP fabrics.Bearings were also replaced at theabutments to accommodate thenew deck displacements. Theproject was carried out verysuccessfully, without interruptionof traffic, and has proven VSL’scapacity to handle verysophisticated retrofit andstrengthening works. ■

Diamond wire base cutting

A complex steel work reinforcing

the structure with a cut-out

system for seismic movements

CFRP application

Installation of the

transversal seismic devices


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Marina Bay Sands® is an integratedresort in Singapore, boasting a2,560-room hotel, a casino with 500 tables and 1,600 slot machines,world-class restaurants, majorarts facilities and 120,000m² ofexhibition space. One of the mostremarkable features is the 340m-long SkyPark, which links the threehotel towers 200m above the groundlevel and includes the world'slargest public cantilevered platform,overhanging the north tower by64m. It offers stunning views of thecity and the Singapore Straits fromits restaurants, 150m-long infinitypool, jacuzzis and gardens.

VSL carried out the heavy liftingworks for the 7,000t steelsuperstructure that supports theSkyPark: 14 heavy lifts of themajor components over a period ofthree months.

VSL’s scope of works for the heavylifting operations included thedesign of approximately 2,100t oftemporary steel structure for thelifts, the methodology, the supplyof temporary VSL CT stress barsand the heavy lifting operationitself.

Lifting the SkyParkThe operation consisted of liftingand sliding a pair of box girders atthe top of Tower 3, lifting six linkbridges between Towers 1 and 2and between Towers 2 and 3, andlifting six segments for the NorthCantilever at Tower 3.The 200m lift of the Tower 3 boxgirders was completed in a single13-hour working day. Each of thetwo 76m-long box girders for Tower 3

SkyPark – lifting a landmaVSL successfully completed the heavy lifting works for7,000t of steel superstructure to support the SkyPark thatnow runs on top of the towers of the Marina Bay Sands®

resort in Singapore.

weighed 760t. Their heights rangedfrom 5m to 10.5m. Two sets oflifting frames were placed on topof the Tower 3 shear walls andoperated simultaneously. The maingirder of each lifting frame wasformed from built-up plate girdersand spliced into different segmentlengths to suit its installation andassembly by tower crane. VSL CTstress bars were used to connectsplice blocks between the girdersegments. Each lifting framerequired four strand lifting unitsfor the operation. SLU-330/550 andSLU-120/550 models were used,together with eight SC31-200hydraulic coilers. Once at the topof the tower, the girders had to beslid by up to 16.7m into position.Lifting of the link bridge girdersbetween towers was carried out

Before each lift, the steel segments

were assembled on the ground.

The observation deck comprises

6 segments, weighing 100-200t each

SPECIAL REPORT

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a B

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ark on Singapore’s skyline

using lifting frames supporting railbeams on the adjacent towers. Thelifting frames were erected on thepermanent structure of the towersat level 55. One SLU lifting unitwas installed on top of a cantileverbeam in order to slide the linkbridge girder along the rail beams.Tower crane obstruction meantthat four of the six link bridgegirders had to have their loadstemporarily transferred onto asliding beam. They were then slidfor approximately 10m before theycould be picked up again by asecond set of lifting units fortransfer to their final positions.

Three strand lifting units and twohydraulic coilers were used inlifting the 53m-long girders, whichweighed between 301t and 391t.As with Tower 3, the wholeoperation was completed in a single working day, with a liftingspeed of 18m/hr.

A pair of self-launching liftingframes was used to lift the sixsegments making up the 64m-longNorth Cantilever. Four SLU lifting

units together with hydrauliccoilers were installed on top of thelifting frame. The equipment hadthe ability to be adjustedindependently in both thetransverse and longitudinaldirections to suit each segment’slifting position. The criticalcompletion schedule led to workbeing carried out around the clockin two shifts, with each segmenttaking 10 hours to lift at a speed of20m/hr. The segment lengthsvaried from 5.7m to 8.5m and theyweighed between 94.7t and 202t.

Providing constructionengineeringVSL had also been involved inseveral earlier key aspects of theconstruction starting with thedesign phase and including the

construction stages using a 3Dbuilding model in Sofistiksoftware. A construction methodwas developed that usedtemporary propping and temporaryvertical post-tensioning in thewalls to ensure that the maximummoments and forces at the basesremained within acceptable limits.

Installing AF anchorageThe temporary works involved theuse of a series of 6-19 cablesrunning inside the shear walls instages from the pile cap up to ashigh as level 23 with three levels ofprops introduced between thevertical and sloping walls. A critical post-tensioningchallenge was the need to providea system that could haveanchorages in the basement raftslab while allowing the verticalcables to be installed and stressedin stages as constructionprogressed. To achieve this, the VSL Type AFFlower Anchorage was used forthe dead end cast inside the pilecap. This unique system makes itfeasible to have a dead-endanchorage in what wouldotherwise be an inaccessiblelocation thus allowing for a muchneater and more elegant andeconomic solution. Successfulproject completion was achieved byclose cooperation of VSL specialiststhroughout the network. ■

Jacks mounted on the

sliding platforms pull

the segments inwards

to their final position.

The segments were lifted at a rate of 15m/h. It took them 13hours to reach 220m.

The last segment for the North Cantilever completed a seriesof spectacular lifts carried out by VSL.

use of the AF anchorage andtemporary tendon installation.(See VSL News Magazine 2008/1and 2009/1). The towers consist ofvertical and sloping walls whichmerge into one at level 23, creatingan A-shaped frame. VSL wasappointed by the main contractor,Ssangyong, to carry out theconstruction engineering for two ofthe three towers, particularly inrelation to the temporary stabilityand geometric control of thevertical shear walls. This involvedchecking the wall forces during the


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TECH SHOW

WORLD FIRST ON CADAGUA BRIDGE

Think lateral for tandem launch


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33

VSL in Spain has overcome severe space constraints and saved

structural steel by devising and carrying out what is believed to

be a unique method for launching two viaducts and their lateral

exit structures. Restricted space between tunnel portals led to

an innovative ‘double-deck’ launching procedure: two main

viaduct structures were launched with a lateral bridge on top.

Each lateral bridge was then manoeuvered into its final

position. Read about the steps of this world first…

The new crossing consists of two main viaductscarrying the road over several secondaryroads, a rail track, the Cadagua River and amotorway, while two lateral bridges carry theexit roads from the main viaducts. All arecomposite bridges with steel box sections.All four bridges are curved in plan withdifferent radius.


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TECH SHOW

B R I D G E L A U N C H I N G

Skid the steel boxes

Only the main viaduct steelboxes were launched and the self-weight ranged from 3.25t/m for thelateral structures to 4.1t/m for themain viaducts. In total, VSL launchedmore than 4,000t of steel structures,with the 364m of the main bridges

3Think lateral

The new crossing consists oftwo main viaducts and two lateralbridges. All are composite bridgeswith steel section. The proposal inthe original scheme had been for allfour bridges to be built up behindthe abutment and launched in pairs

1 Take care of the long nose

Two SLU 70 hydraulic strandlifting units installed in a steel gantryon the receiving pier catered for the3.6m front deflection of the steellaunching nose at the maximumcantilever of 102m.

2

being launched in eight phases.During all launching phases thevertical loads and level at theabutment, towers and piers werecontinuously monitored and adjustedas per the calculation requirements.In all these skidding points, two jacksof 500t capacity and 600mm-strokewere supplied by VSL.

(at the same level), but this createdsome significant issues because ofthe variable distance between theirlongitudinal axes, ranging from1.95m to 5.14m. VSL proposed thatthese issues could be overcome byassembling each lateral bridge ontop of the corresponding mainviaduct before a ‘double-deck’launch. The lateral bridges couldthen be skewed and slid beforebeing lowered to their final position.The proximity of the tunnel portal tothe launching abutment left only55m for superstructure assembly.VSL increased that space by erectingtemporary steel towers between theabutment and the first pier toprovide a platform for manufacturingand skidding the bridge sections.


35

N E W S N ° 2 - 2 0 1 0

Skew and slide at the piers

VSL also designed andsupplied a skidding system allowingrotation of the lateral bridges at thepiers. This involved a line of 10m ofthe VSS 500t skidding system, with aflat skid beam of 4.5m and a push-pull unit of 56t.

4

Use custom made gantries

Two sets of equipment wereinstalled behind the abutment – oneset for each of the main launches.Each included two pairs of 300tmechanical skidding supports, threepairs of 225t jacks and two hydraulicstrand-pulling units. Once each mainlaunch was completed, VSL installed300t-capacity steel gantries on thetwo main piers to skid and lower thelateral bridges to their final position.

5

Lift and lower the lateral bridges

Each gantry on the main piers includeda standard VSS transversal skidding system aswell as SMU hydraulic strand units for liftingand lowering the lateral bridge. A standard 250t-capacity crane completed theequipment list for one of the lateral bridgesinstallation.

6


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TECH SHOW


Value engineering for an

extraordinary project

The main viaducts have a total lengthof 364 m/each divided into four spansranging from 80m to 102m. All fourbridges are curved in plan (withdifferent radius) and the longitudinalslope for the main viaducts meantthat the bridges were always beinglaunched uphill at gradients from 2% to 3%.

7


37

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TECH SHOW


N E W S N ° 2 - 2 0 1 0

Provide savings

VSL’s scope of works included the launching of the complete steelstructure for the two main viaducts plus the skidding and lowering operationsfor the two lateral approach structures, including developing the detailedengineering. VSL also supplied all the permanent pot bearings for the link andthe temporary stay cables for one of the lateral bridges. VSL’s revised procedureinvolved a great deal of engineering but its adoption offered several advantages,including a considerable reduction in the space required at the abutment. Thisalso allowed savings in the amount of temporary and structural steel required.Even though equipment changes were required, the VSL scheme proved cheaperfor the client than the original proposals and brought benefits to the overallproject schedule.

8


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C R E AT I N G S O L U T I O N S T O G E T H E R

www.vsl.com

TAIWANVSL Taiwan Ltd.TAIPEIPhone: +886 2 2759 6819Fax: +886 2 2759 6821

THAILANDVSL (Thailand) Co. Ltd.BANGKOKPhone: +66 2 679 76 15 - 19Fax: +66 2 679 76 45

VIETNAMVSL Vietnam Ltd.HANOIPhone: +84 4 3976 5088Fax: +84 4 3976 5089

HO CHI MINH CITYPhone: +84 8 810 6817Fax: +84 8 810 6818

Australia

VSL Australia Pty. Ltd.NEW SOUTH WALESPhone: +61 2 9484 5944Fax: +61 2 9875 3894

QUEENSLANDPhone: +61 7 3265 64 00Fax: +61 7 3265 75 34

VICTORIAPhone: +61 3 979 503 66Fax: +61 3 979 505 47

SOUTH AUSTRALIAPhone: +61 8 8354 4884Fax: +61 8 8354 4883

TASMANIAPhone: +61 3 6225 3567Fax: +61 3 6225 2226

PERTHPhone: +61 8 9523 4686Fax: +61 8 9875 84 22

Americas

ARGENTINAVSL Sistemas Especiales deConstrucción Argentina SABUENOS AIRESPhone: +54 11 4326 06 09Fax: +54 11 4326 26 50

BOLIVIAPostensados de BoliviaSan Miguel, La PazPhone: +591 2 27 70 338Fax: +591 2 27 96 183

CHILEVSL Sistemas Especiales deConstrucción S.A.SANTIAGOPhone: +56 2 571 67 00Fax: +56 2 571 67 01

COLOMBIASistemas Especiales de Construcción S.A.SBOGOTAPhone: +57 1 226 62 30Fax: +57 1 271 50 65

MEXICOVSL Corporation Mexico S.A de C.VMEXICOPhone: +52 55 55 11 20 36Fax: +52 55 55 11 40 03

PERUSistemas Especiales de ConstrucciónPeru S.A.LIMAPhone: +51 1 349 38 38Fax: +51 1 348 28 78

UNITED STATESVStructural LLCBALTIMORE, MDPhone: +1 410 850 7000Fax: +1 410 850 4111

VENEZUELAGestión de Obras y Construcciones C.A.CARACASPhone/Fax: +58 212 941 86 75

Africa

EGYPTMatrix Engineering CompanyCAIROPhone: +20 2 344 19 00Fax: +20 2 346 04 57

SOUTH AFRICATsala-RMS Construction Solutions (Pty) LtdJOHANNESBURGPhone: +27 11 878 6820Fax: +27 11 878 6821

Europe

AUSTRIAGrund-Pfahl- und Sonderbau GmbHHIMBERGPhone: +43 2235 87 777Fax: +43 2235 86 561

CROATIATehnicki projekt d.o.o.ZAGREBPhone: +385 1 4664 586Fax: +385 1 4664 549

CZECH REPUBLICVSL Systems (CZ) Ltd.PRAGUEPhone: +420 2 51 09 16 80Fax: +420 2 51 09 16 99

FRANCEVSL France S.A.LABÈGEPhone: +33 05 61 00 96 59Fax: +33 05 61 00 96 62

GERMANYVSL Systems GmbHBERLINPhone: +49 30 530 28 06-0Fax: +49 30 530 28 06-99

GREAT BRITAINVSL Systems (UK) Ltd.LUTONPhone: +41 148 040 44 01Fax: +41 148 040 44 02

NETHERLANDSHeijmans Beton en Waterbouw B.V.ROSMALENPhone: +31 73 543 66 02Fax: +31 73 543 66 11

NORWAYSpennarmering Norge ASRUDPhone: +47 98 21 02 66Fax: +47 67 17 30 01

POLANDVSL Polska Sp. Zo.oWARSZAWAPhone : +48 22 849 22 09Fax : +48 22 849 02 23

PORTUGALVSL Sistemas Portugal SedeQuinta da FontePAÇO DE ARCOSPhone: +351 21 445 83 10Fax: +351 21 444 63 77

Delegação NorteVILA NOVA DE GAIAPhone: +351 22 371 18 80Fax: +351 22 371 19 16

Asia

BRUNEI VSL Systems (B) Sdn. Bhd.BRUNEI DARUSSALAMPhone: +673 2 380 153 / 381 827Fax: +673 2 381 954

CHINA PRCVSL (China) Engineering Corp., Ltd.HEFEIPhone: +86 551 382 29 18Fax: +86 551 382 28 78

HONG KONGVSL Hong Kong Ltd.CHAI WANPhone: +852 2590 22 88Fax: +852 2590 02 90

Intrafor Hong Kong Ltd.CHAI WANPhone: +852 2836 31 12Fax: +852 2591 61 39

FT Laboratories Ltd.PING CHEPhone: +852 2758 48 61Fax: +852 2758 89 62

INDIAVSL India PVT Ltd.CHENNAIPhone: +91 44 4225 11 11Fax: +91 44 4225 10 10

INDONESIAPT VSL IndonesiaJAKARTAPhone: +62 21 570 07 86Fax: +62 21 573 75 57

JAPANVSL Japan CorporationTOKYOPhone: +81 3 3346 8913Fax: +81 3 3345 9153

KOREAVSL Korea Co. Ltd.SEOULPhone: +82 2 553 8200Fax: +82 2 553 8255

MALAYSIAVSL Engineers (M) Sdn. Bhd.KUALA LUMPURPhone: +603 7981 47 42Fax: +603 7981 84 22

PHILIPPINESVSL Philippines Inc.PASIG CiITYPhone/Fax: +632 672 13 95

SINGAPOREVSL Singapore Pte. Ltd.SINGAPOREPhone: +65 6559 12 22Fax: +65 6257 77 51

SPAINCTT StrongholdBARCELONAPhone: +34 93 289 23 30Fax: +34 93 289 23 31

VSL-SPAM, S.A.BARCELONAPhone: +34 93 846 70 07Fax: +34 93 846 51 97

SWEDEN / NORWAYInternordisk Spännarmering ABVÄSTERHANINGEPhone: +47 98 21 02 66Fax: +47 67 17 30 01

SWITZERLANDVSL (Switzerland) Ltd.SUBINGENPhone: +41 58 456 30 30Fax: +41 58 456 30 35

VSL (Suisse) SASAINT LEGIERPhone: +41 58 456 30 00Fax: +41 58 456 30 95

TURKEYMega Yapi Construction & Trade Co. LtdANKARAPhone: +90 312 490 90 66Fax: +90 312 490 90 55

UNITED KINGDOMVSL System (UK) LtdLUTONPhone: +44 148 040 44 01Fax: +44 148 040 44 02

Middle East

SYRIAKahaleh for consulting engineeringDAMASCUSPhone: +963 232 47 02Fax: +963 11 22 14 595

UNITED ARAB EMIRATESVSL Middle East LLCDUBAI, UAEPhone: +971 4 885 7225Fax: +971 4 885 7226

DOHA, QATARPhone: +974 423 1117Fax: +974 423 1100

HEADQUARTERS

VSL International Ltd.

Saegestrasse 76

CH-3098 Köniz - Switzerland

Phone: +41 58 456 30 00

Fax: +41 58 456 30 95

email: [email protected] VSL LOCATIONS

^


SYSTEMS & TECHNOLOGIES

• Post-tensioning strand systems

• Bars & post-tensioning bar systems

• Stay cable systems

• Damping systems (stays & buildings)

• Ductal® UHP concrete

• Bearings & Joints

www.vsl.com

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Abu Dhabi: The place to be? Sky Park lift at Marina Sands ...

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